Head Gasket Failure - Help & Advice Needed

[lewis205cti 12]

Hi all

 

So I’m needing some advice/opinions.

My 309 (not a 205 i know) GTI has suffered a head gasket failure. The engine has covered over 160K and is need of a few tweaks too.

 

I have removed the head and the gasket is totally gone. Looks to have just given up with age. But cylinder two is also looking a tad suspect.

When removing the head 9 of the head bolts removed with no problem after soaking and impacting them. They were removed in the correct sequence too.

By you guessed it one of the bolts snapped off in the block/ about an inch inside the block from being flush.

 

 

 

 

Looking at the broken bolt it’s totally rotten and rusted so I suspect that the gasket started to seep their first causing the bolt to rust solid into the ally block.

The bolt did not snap evenly too. I’m currently soaking the remainder of the bolt in the block with penetrating fluid. This weekend I’m planning to heat the block and trying to drill and easy-out the remainder of the bolt. But I don’t know how successful this will be. Any Ideas?

 

 

 

 

So right now I’m looking at a full gasket set (exhaust, cylinder, cam over etc) full timing belt kit (belt, water pump and tensioner)

Getting the cylinder head skimmer in case it’s warped. Or a shim?

Investigating cylinder 2

Set of new head bolts

Fluids

Etc

 

That’s if I can get the broken bolt out or the block drilled and helicoiled.

So I’m wondering if I should just source a complete GTI-6 lump, give it a belt change and service and drop that in the 309?

The cost of the engine and parts I believe will be similar to fixing the 8v lump that has covered high mileage.

 

If I was to go down the GTI-6 route I’m happy to remove the 8v lump and get the 16v engine in the car as I believe the engine mounts are the same etc. Or there I a few guides about . But the exhaust adaption and wiring is what I’m not too sure on.

 

I live in High Wycombe (Bucks) so I could get the car recovered to somewhere like Miles’ garage. But trying to keep the costs down. Do any of you know of a garage local to me that will get the engine running in my car and that will do a good job. Or any of you useful lot know how to and want to earn some cash? I will help where possible if needed.

 

Ideally I want to keep the costs as low as possible and the Mrs is already on about scrapping it due to me having a newer pug. But I’m not going too as it’s a good example and too much fun to drive.

 

All thoughts welcome

Cheers

Lewis

 

[welshpug 1,662]

Rebuilding an 8v engine is far cheaper than installing a gti6 properly.

 

Have you got the head off now?

[Tom Fenton 1,542]

If you are going to attempt to get the broken bolt out of the block in the car the best way to go about it is to hire a mag mount drill and bolt a steel plate down to the block top surface. That will allow you to accurately centre the drill and will ensure that you drill down central and square- you have only got one go at it so you need to get it right.

I've helicoiled a couple, you want double length helicoils to do a good job of it.

[lewis205cti 12]

Thanks tom for the advice. I will give it a go. I'll post back how I get on.

[lewis205cti 12]

Yes the head is off the engine. The gasket was shot. Sorting that and putting it all back together should be ok. But the hard bit will be getting the broken bolt out. I will give toms method a go and see how I get on. Thanks

[Tom Fenton 1,542]

It is a faff sorting it out, but worth it, as it would be difficult doing it freehand with a pistol drill.

To expand on above, get yourself a cutter that is the same size as the hole on the block top surface. You can use this to set the mag drill up. Then swap to your drill but without moving it and off you go.

[Anthony 1,003]

Alternatively, it might be worth just picking up a complete replacement 1.9 engine given that they're not too costly.

 

Obviously that depends if you're in a position to do an engine swap yourself as to whether that option would be economical/realistic.

[lewis205cti 12]

Thanks guys. Going to try drilling it out first. If not I'll swap out the engine. There is a few on ebay that might be ok. Fingers crossed. I'll update on my progress.